U.S. patent number 10,202,905 [Application Number 14/865,838] was granted by the patent office on 2019-02-12 for gas turbine architecture.
This patent grant is currently assigned to ROLLS-ROYCE DEUTSCHLAND LTD & CO KG. The grantee listed for this patent is Rolls-Royce Deutschland Ltd & Co KG. Invention is credited to Gideon Daniel Venter.
United States Patent |
10,202,905 |
Venter |
February 12, 2019 |
Gas turbine architecture
Abstract
A geared architecture for a gas turbine comprising an output
shaft for connection with a fan, an input shaft and a gearbox
connecting the input shaft with the output shaft. The gearbox has a
forward planet carrier plate supported by a forward radially fixed
bearing structure and a rearward planet carrier plate supported by
a rearward radially fixed bearing structure. By supporting the
carrier plates on radially fixed bearing structures the planet
carriers can rotate about their own axis to lower vibration and
mesh forces within the gearbox.
Inventors: |
Venter; Gideon Daniel (Berlin,
DE) |
Applicant: |
Name |
City |
State |
Country |
Type |
Rolls-Royce Deutschland Ltd & Co KG |
Dahlewitz |
N/A |
DE |
|
|
Assignee: |
ROLLS-ROYCE DEUTSCHLAND LTD &
CO KG (Dahlewitz, DE)
|
Family
ID: |
51946800 |
Appl.
No.: |
14/865,838 |
Filed: |
September 25, 2015 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20160097330 A1 |
Apr 7, 2016 |
|
Foreign Application Priority Data
|
|
|
|
|
Oct 3, 2014 [GB] |
|
|
1417504.6 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F02C
7/36 (20130101); F01D 25/04 (20130101); F02K
3/04 (20130101); F02C 7/06 (20130101); F01D
15/12 (20130101); F02C 3/04 (20130101); F05D
2260/40311 (20130101); F05D 2260/96 (20130101); F16H
2057/085 (20130101) |
Current International
Class: |
F02C
7/36 (20060101); F01D 15/12 (20060101); F02C
7/06 (20060101); F02C 3/04 (20060101); F02K
3/04 (20060101); F16H 57/08 (20060101); F01D
25/04 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
2327859 |
|
Jun 2011 |
|
EP |
|
2518279 |
|
Oct 2012 |
|
EP |
|
1 363 151 |
|
Aug 1974 |
|
GB |
|
14182467 |
|
Nov 2014 |
|
WO |
|
2014182467 |
|
Nov 2014 |
|
WO |
|
Other References
Feb. 17, 2016 Search Report issued in European Patent Application
No. 15 18 6894. cited by applicant .
Feb. 17, 2016 Search Report issued in European Patent Application
No. 15 18 6893. cited by applicant .
U.S. Appl. No. 14/866,113, filed Sep. 25, 2015 in the name of
Gideon Daniel Venter. cited by applicant .
Apr. 1, 2015 Search Report issued in British Patent Application No.
GB1417504.6. cited by applicant .
Mar. 30, 2015 Search Report issued in British Patent Application
No. GB1417505.3. cited by applicant .
Oct. 2, 2017 Office Action issued in U.S. Appl. No. 14/866,113.
cited by applicant .
Apr. 16, 2018 Office Action issued in U.S. Appl. No. 14/866,113.
cited by applicant.
|
Primary Examiner: Kraft; Logan
Assistant Examiner: Wong; Elton
Attorney, Agent or Firm: Oliff PLC
Claims
The invention claimed is:
1. A geared architecture for a gas turbine, comprising: an output
shaft for connection with a fan; an input shaft; a gearbox
connecting the input shaft with the output shaft, the gearbox
having a forward carrier directly supported by a forward radially
fixed bearing structure; and a rearward carrier supported by a
rearward radially fixed bearing structure, wherein a flexible
coupling is provided between the output shaft and the forward
carrier.
2. A geared architecture according to claim 1, wherein the gearbox
is an epicyclic gearbox having a central sun gear and a plurality
of planet gears adapted to orbit the sun gear.
3. A geared architecture according to claim 2, wherein the forward
carrier comprises a plurality of planet pins extending into the
gearbox, each planet pin supporting a planet gear.
4. A geared architecture according to claim 3, wherein each planet
gear is supported on a respective planet pin by a spherical joint
permitting relative movement of the planet pin and planet gear.
5. A geared architecture according to claim 3, wherein the forward
carrier comprises a forward extending flange, the flange having a
radially outer surface supported by the forward fixed bearing
structure.
6. A geared architecture according to claim 5, wherein the flexible
coupling comprises a hollow annular connector between a fan shaft
and the forward extending flange, the annular connector having a
radially outwardly extending first wall joined to the fan shaft, a
radially outwardly extending second wall joined to the forward
flange and a curved radially outer periphery joining the first and
second walls.
7. A geared architecture according to claim 6, wherein the curved
radially outer periphery diverges in an axial direction before
converging in opposing axial direction.
8. A geared architecture according to claim 2, wherein the rearward
radially fixed bearing structure has a lubricant transfer coupling
for the supply of lubricant to the gearbox.
9. A geared architecture according to claim 8, wherein the rearward
carrier has an internal passage for the supply of lubricant from
the lubricant transfer coupling to the gearbox.
10. A geared architecture according to claim 9, wherein the
internal passage has an inlet adjacent the lubricant transfer
coupling and one or more outlets adjacent one or more gears in the
gearbox.
11. A geared architecture according to claim 1 wherein the gearbox
comprises a radially outer ring gear flexibly mounted to a fixed
structure.
12. A geared architecture according to claim 11, wherein the ring
gear two axially spaced gear regions separated by a non-geared
region and wherein each gear region is separately mounted to the
fixed structure by respective flexible mounts.
13. A geared architecture according to claim 12, wherein the
separate flexible mounts attach to the fixed structure at a common
location point.
14. A geared architecture according to claim 13, wherein a first
one of the flexible mounts extends axially forward from the common
location point to a respective gear region and a second one of the
flexible mounts extends axially rearward from the common location
point to a respective gear region.
15. A geared architecture for a gas turbine, comprising: an output
shaft for connection with a fan; an input shaft; a gearbox
connecting the input shaft with the output shaft, the gearbox being
carried in the gas turbine by a forward radially fixed bearing
structure and a rearward radially fixed bearing structure, the
gearbox being directly supported by the forward radially fixed
bearing structure and the rearward radially fixed bearing
structure, wherein a flexible coupling is provided between the
output shaft and the gearbox.
Description
The present invention relates to a gearing architecture
particularly for a gas turbine engine and particularly for a
gearing architecture between a compressor and a fan stage in a gas
turbine engine.
In recent years there has been an increased focus on fuel
efficiency in the aerospace industry that has led to the provision
of turbofan engines with low pressure fans of increased size and
greater bypass ratios.
The fan of a gas turbine engine is driven by a shaft from the
turbine. The efficiency of the fan depends on its rotational
velocity and in order to operate efficiently the fan must rotate at
a rotational velocity that is within a given range. To achieve the
required rotational velocity the turbine is split into high,
intermediate and low pressure sections with the high pressure
turbine driving the high pressure compressor, the intermediate
pressure turbine driving the immediate pressure compressor and the
low pressure turbine driving the fan. Each section of the turbine
is configured to rotate at a suitable rotational velocity. Shafts
connect the respective turbine and compressor components. In this
way the rotational velocity of the fan can be matched to the
rotational velocity of the low pressure turbine and this rotational
velocity can be different to the rotational velocity (and direction
of rotation) of the other turbine or compressor components.
In a geared fan arrangement a reduction gearbox is provided to
reduce the speed from the low pressure turbine to the fan. The use
of a reduction gearbox allows both the fan and the low pressure
turbine to operate at optimal speeds resulting in minimum fan noise
and optimum low pressure turbine efficiency. This enables the use
of a smaller low pressure turbine that reduces engine weight,
length and radial engine size since the same work is done with
fewer and smaller turbine stages compared to a low pressure turbine
that is coupled directly to the fan.
The reduction gearbox has an input shaft that is coupled to the low
pressure turbine shaft through a splined joint from the
intermediate pressure compressor and an output shaft leading to the
fan. Significant forces are transferred through the gearbox and any
misalignments between the many parts of the gearbox, or the input
or output shafts can lead to increased wear and/or damage to the
gearbox. Such misalignments could be caused, for example by
manufacturing non-conformance, gyroscopic loads during engine
operation or assembly misalignments.
It is an object of the present invention to seek to provide an
improved gearing architecture for a gas turbine engine that seeks
to address this, and other problems.
According to an aspect of the invention there is provided a geared
architecture for a gas turbine, comprising: an output shaft for
connection with a fan; an input shaft; a gearbox connecting the
input shaft with the output shaft, the gearbox having a forward
planet carrier plate supported by a forward radially fixed bearing
structure; and a rearward planet carrier plate supported by a
rearward radially fixed bearing structure.
According to an aspect of the invention there is provided a geared
architecture for a gas turbine, comprising: an output shaft for
connection with a fan; an input shaft; a gearbox connecting the
input shaft with the output shaft, the gearbox being carried in the
gas turbine by a forward radially fixed bearing structure and a
rearward radially fixed bearing structure.
By supporting the carrier plates or gearbox on radially fixed
bearing structures the planet carriers can rotate about their own
axis to lower vibration and mesh forces within the gearbox. This
accurate rotation about an axis can limit a number of technical
issues such as: significant vibration, excessive structural loads,
excessive bearing loads, excessive gear mesh loads and increased
leakage at oil transfer couplings.
The bearings in the fixed bearing structure may be roller bearings
that may be mounted in an annular race. The bearing structure may
be part of the fan bearing support structure. Other bearing
arrangements may be used as appropriate.
The roller bearings can also prevent displacement caused by
gyroscopic loads ensuring that no additional loads are transferred
to the gears and bearings allowing an optimised gearbox design.
A flexible coupling may be provided between the output shaft and
the forward carrier plate.
The flexible coupling further helps to isolate the gearbox from
external loads induced by misalignment or by transient loads
experienced during flight manoeuvres or by foreign object
impact.
Isolating the gearbox from external loads allows the gearbox
components that would otherwise have to be designed to cope with
higher loads to be made smaller resulting in a decrease in the
gearbox size and weight. Weight also affects engine vibrational
behaviour and the measures required to counter the effects
especially in cases like fan blade off and windmilling post fan
blade off. A larger gearbox will also limit the space available for
the fan support structure, bearings and fan blade off fusing
features where a minimum axial distance is required to ensure
adequate bearing span.
Supporting one or both of the planet carrier plates by a radially
fixed bearing structure help to direct gyroscopic loads into the
bearing structure to minimise additional gear mesh and bearing
loads.
Preferably the gearbox is an epicyclic gearbox having a central sun
gear and a plurality of planet gears adapted to orbit the sun
gear.
The central sun gear may be driven by the input shaft that connects
between gas turbine intermediate pressure compressor and the gear
box. A portion of the input shaft may also be supported by part of
the rearward radially fixed bearing structure.
The planet gears may be connected to the forward planet
carrier.
The forward planet carrier plate may comprise a plurality of planet
pins extending into the gearbox, each planet pin supporting a
planet gear.
There may be five planet gears.
Each planet gear may be supported on a respective planet pin by a
spherical or ball joint permitting relative movement of the planet
pin and planet gear.
The spherical joint can compensate for slight pitch changes of the
carrier plate or deflection of the planet pins and assist in the
continuing alignment of the planet gears with the sun and ring
gears to limit the load and wear that could be caused by the meshed
gearing. The spherical joint may be located midway along the axial
length of the planet gear to assist in minimising torsional wind-up
or moments around the joint.
The planet carrier may also comprise a forward extending flange,
the flange having a radially outer surface supported by the forward
fixed bearing structure.
The planet carrier may also have an axially forward face to which
the flexible coupling is secured by bolts or other mechanism. The
flexible coupling may be integrally formed with the planet
carrier.
The flexible coupling may comprise a hollow annular connector
between a fan shaft and the forward extending flange, the annular
connector having a radially outwardly extending first wall joined
to the fan shaft, a radially outwardly extending second wall joined
to the forward flange and a curved radially outer periphery joining
the first and second walls.
The flexible coupling may be provided by a composite material made
by a laminate of plies of e.g. a glass, aramid or carbon fibre
embedded within a resin such as an epoxy or other appropriate
material. Alternatively, the flexible coupling may be metallic or
another appropriate material.
The flexible coupling may be torsionally stiff but axially
compliant. Torsional deflection will result in gear tooth and
bearing misalignment causing local overloads. To counter this gear
tooth profiles and bearing rolling elements need to be modified to
improve the loading characteristics. The modification will be
applied for a specific load condition where the components are
expected to operate for the bulk of the time. This will result in a
compromise for other load settings. Gear tooth and rolling element
modification however reduces the effective contact areas requiring
a further increase in size to compensate.
The exact form of the flexible couplings is subject to finite
element modelling analysis and can either be a flow formed single
or welded component or loose parts that are bolted together.
Through design optimum space utilisation with functionality to suit
the available space and operational conditions is possible.
The rearward radially fixed bearing structure may have a lubricant
transfer coupling for the supply of lubricant to the gear box.
The lubricant transfer coupling is located close to the gearbox and
carrier location bearing to help reduce leakage and loss from the
lubricant system. This reduces the overall amount of lubricant
required and the required capacity of the pumps and tanks
associated with the lubricant system. The smaller sizes of the
components helps lower the weight of the system.
The lubricant transfer coupling may further comprise a passage from
an oil sump.
The rearward carrier plate may have an internal passage for the
supply of lubricant from the lubricant transfer coupling to the
gear box.
The carrier plate may have a radial portion and a cylindrical
projection that extends axially rearward from the flange. The
internal passage may extend within both the radial portion and the
cylindrical projection. Within the cylindrical projection the
passage may be annular. Within the radial portion the passage may
be a single circular cavity or may be provided by a plurality of
radial passages projecting from the passage in the cylindrical
portion.
The internal passage may have an inlet adjacent the lubricant
transfer coupling and one or more outlets adjacent one or more
gears in the gearbox. The outlets can supply lubricant to the sun
gear, the planet gears and/or a radially outer ring gear.
The inlet may be located in the cylindrical projection. The one or
more outlets may be provided in the radial portion.
Where the gearbox comprises a radially outer ring gear, the gear
may be flexibly mounted to a fixed structure. The ring gear may
comprise two axially spaced gear regions of opposite hand separated
by a non-geared region. Each gear region may be separately mounted
to the fixed structure by respective flexible mounts. The ring gear
may be static or rotating.
The separate flexible mounts may attach to the fixed structure at a
common location point.
A first one of the flexible mounts may extend axially forward from
the common location point to a respective gear region and a second
one of the flexible mounts extends axially rearward from the common
location point to a respective gear region.
An embodiment will now be described by way of example only and by
reference to the accompanying drawings, in which:
FIG. 1 depicts a cross section through the front end of a gas
turbine engine having a gear architecture 10 in accordance with the
present invention for use in a gas turbine engine.
FIG. 2 depicts a further cross section through the front end of a
gas turbine engine having a gear architecture 10 in accordance with
the present invention for use in a gas turbine engine.
FIG. 1 depicts a cross section through the front end of a gas
turbine engine having a gear architecture 10 in accordance with the
present invention for use in a gas turbine engine. The gas turbine
engine has a fan stage that has a circumferential array of fan
blades 12 mounted to a fan disc 14. The blades and disc rotate
around the engine axis 2. A plurality of axially extending slots
are machined into the radially outer surface of the fan disc and
these are shaped to receive a correspondingly shaped feature that
is provided on the root of the fan blade. Alternatively the fan
blades may be integrally formed with the disc hub.
An annulus filler and fan fairing 18 provides a smooth surface over
which the air passes as it approaches the fan stage and is pushed
rearwards by the fan. The fan fairing is mounted to and supported
by the fan disc.
The disc is mounted on a fan shaft 16 that is a cylindrical
component extending about the engine axis 2. The disc and shaft
together support all the rotating components forward of the gearbox
and can experience bending moments from the fan either in normal
flight operation as the engine undergoes acceleration or manoeuvre,
or in extremely rare failure conditions such as when the a blade is
hit by foreign objects that cause the release or deformation of one
or more of the blades.
The fan shaft has a support mechanism that includes a forward
bearing 20 that supports the fan shaft in its radial position
through a support arm 22. A location bearing 24 serves to limit the
axial movement of the fan shaft within the engine. The fan shaft is
connected to the output side of the gearbox 25.
The gearbox input shaft 26 connects between the turbine and the
gearbox 25. The shaft is supported by a bearing arrangement 28 that
serves to locate the shaft radially within the engine with a
support structure 30 that extends through to the engine casing. The
input shaft can have slight eccentricity from the engine axis 2
caused by engine deformation and/or misalignment.
The fan reduction gearbox 25 can be either a simple star or
planetary epicyclic arrangement using double helical gears to
ensure highest power to weight ratio. The reduction ratio will
determine the max number of planets that can be fitted
circumferentially. In the embodiment shown the gearbox 25 is a
planetary epicyclic gearbox having a central sun gear 44, planet
gears 42 that orbit the sun gear and a ring gear 60a, 60b. A
forward planet carrier plate 46 has a series of pins 49 that engage
the planet gears such that the planet carrier rotates around the
engine axis at the same speed that the planet gears orbit the sun
gear.
The forward carrier 46 has a forwardly extending flange 45 that is
supported by a support bearing 47 carried by a structure 51 that
transmits loads to the engine casing. The bearing is at a fixed
axial and radial location relative to the engine axis 2 and
inhibits radial translation of the flange.
The bearings may be roller bearings mounted in an annular bearing
race. Other bearings as deemed appropriate may be used.
A rear carrier plate 48 and the forward carrier plate support the
planet bearings 50. The rear carrier plate has extensions that
protrude between the respective planet gears and are attached to
the forward carrier single plate with free standing pins. The rear
carrier also has an axially rearwardly extending cylinder that is
supported by bearings 28 carried by input shaft support structure
30. The rear carrier provides radial support for the rear roller
bearing as well as offering an oil supply circuit and feed passages
to supply oil for lubrication to the planet bearings, gear mesh,
sun gear spline and fan shaft bearing. The rear support structure
30 serves to locate the rear carrier at a fixed axial and radial
position relative to the engine axis 2.
The bearings may be roller bearings mounted in an annular bearing
race. Other bearings as deemed appropriate may be used.
Supporting the gearbox carriers on bearings that are mounted at a
fixed radial location and optionally permitting at least some of
the other gear components such as the ring and sun gears to be more
flexibly mounted such that they can move relative to the carrier
aids the ability of the planet carrier to rotate around its own
axis to ensure lower vibration.
An oil transfer coupling 56 is located close to the rear roller
bearing 28. This positioning keeps the radial clearance and shaft
run out relative to the bearing support structure at a minimum to
reduce oil leakage and improve sealing reliability since the roller
bearing has limited radial clearance.
The oil transfer coupling supplies lubricant to the cylindrical
portion of the rear carrier that has an internal annular passage
that extends axially forward to the radial plate and then turns to
extend radially either as a single circular passageway or as a
series of spokes. The inlet to the annular passage may be a
continuous passage extending around the periphery of the
cylindrical portion or the inlet may be a series of
circumferentially spaced apertures.
In order to increase the power density and to avoid axial loads
reacting on the gearbox, double helical ring gears 60a, 60b are
used. The ring gear is produced in two halves to simplify assembly
to the planet gears. The axial force applied on the ring gear
halves resulting from the gear mesh are a result of the helix angle
as well as the hand of helix. These are selected to direct the
direct the axial force towards the other ring gear half. There is a
non toothed section 60c between the ring gear halves that has
cutouts or apertures that enable oil drainage from the gear mesh
area. The position of these holes allow oil that is ejected through
the upper part of the gearbox to collect in a gutter and drained to
the oil collection point from where it will be scavenged away
rather than draining back into the gearbox.
The two ring gear halves each feature an axially centred attachment
flange 62 to help avoid torsional wind up. Each ring gear half is
attached to the engine structure by separate flexible diaphragm
supports 64. It is desirable that the diaphragm supports are
symmetrical to each other and mounted to the engine structure at a
common position to minimise torsional wind up or unequal moments
across the width of the gear. The flexible supports allow
independent radial displacement of the respective ring gear halves
to ensure optimal meshing conditions and to counter manufacturing
variations. The flexible supports are axially compliant and are not
required to keep the two ring gear halves together, the axial
movement being limited by the gear angle and gear hand of the
double helix ring gear.
The flexible supports can feature circumferential drainage holes to
drain the oil completely away from the gearbox and together can
define a channel to direct the oil towards an oil sump.
Supporting the gearbox carriers on bearings that are mounted at a
fixed radial location and additionally permitting at least some of
the other gear components such as the ring and sun gears to be more
flexibly mounted such that they can move relative to the carrier
aids the ability of the planet carrier to rotate around its own
axis to ensure lower vibration.
The location of an oil transfer coupling in close proximity to one
of the bearings helps in that it provides good centring for the oil
transfer coupling with minimal leakage.
To limit the fan bending moments being transferred to the gearbox
and therefore being reacted by the gearbox a flexible coupling
feature 70 that is axially compliant but torsionally stiff is
introduced between the fan shaft and the carrier. This feature is
connected to the planet carrier close to the planet carrier
bearings to react any fan induced loads to the engine casing rather
than through the gearbox.
In the embodiment shown the flexible coupling feature is a hollow
ring defining a cavity open at its inner periphery and with a
continuous wall extending along a first side, around the radially
outer end and along a second side to the inner periphery.
Both the first and second side walls are substantially parallel but
each wall diverges and subsequently converges to provide the
radially outer end with a bulbous form. The flexible coupling
feature may be symmetrical around a central axis and also
symmetrical about a plane that bisects the radially outer end and
the inner periphery.
The fan is connected to the output side of the gearbox. If there is
no flexibility in the fan drive shaft, fan bending moments under
all flight and failure conditions will be reacted on the fan
reduction gearbox increasing the loads on the gear teeth and
bearings. This will require that the respective components needs to
be sized accordingly to accommodate the additional loads.
As discussed earlier the planet carrier is a plate with pins on
which the planet gears with integrated planet bearings and
spherical joints are mounted. This plate is directly connected to
the flexible coupling that is axial compliant but torsional stiff
to ensure the shortest load transfer to the fan. The planet pins
have a spherical joint positioned in the axial centre of the planet
gears. By positioning these spherical joints in the axial centre it
is possible to minimise torsional wind-up or moments around the
joint. When the load is applied through the gearbox the pins
cantilevered from the forward carrier plate are permitted to
deflect but their displacement is compensated for by the spherical
joints that ensures that the planet gears remains aligned in the
plane of the meshing gears.
To minimise the engine bending moments being transferred to the
gearbox and therefore being reacted by the gearbox the power of the
low pressure turbine shaft is transferred by a flexible shaft 27
that helps to ensure that any eccentricity between the turbine
shafts and the sun gear is accommodated without excessive
misalignment in the shaft to sun gear spline connection. This
allows the sun gear to find its natural position during operation.
The spline interface between the flexible shaft and the sun gear is
aligned axially to the gear centre to avoid torsional wind up or
unequal moments across the width of the gear thereby maximising
meshing and loading conditions. The bolted joints in shaft 27
increase its flexibility.
In the embodiment shown the forward carrier plate has a forwardly
extending flange in the shape of a cylinder that extends around the
axis of the gear box. The cylinder has a radially outer surface
that is located in a fixed axial and radial location by the bearing
structure 47. The forward surface of the cylinder has a series of
apertures through which bolts or other mounting pins are inserted.
The bolts also extend through part of the flexible coupling to
secure it to the forward carrier plate. A similar bolting
arrangement secures the flexible coupling to the output shaft
16.
In an alternative arrangement shown in FIG. 2, the flexible shaft
71 is a one piece construction having a splined end that extends
axially, then radially outwards, through a curve and then radially
inwardly to a bolting surface that is joined to planet carrier
drive pins 15 by a bolted arrangement. Where possible the reference
numerals used are the same as those of FIG. 1.
The gearbox arrangements assist in the equal sharing of load
between the planets and the respective gear banks of the double
helical gears despite manufacturing tolerances, thermal and load
deformation as well as external load inputs from the engine causes
uneven loading and misalignment of the gear meshes. Any shaft
deformation or misalignment that will result in a relative offset
between the gearbox and engine axis will introduce unsymmetrical
gear teeth and bearing loading.
In the case of a planetary gear arrangement the carrier is rotating
and is normally radially centralised by the sun and planet gear
mesh forces. Due to tooth errors and manufacturing variances, the
mesh forces will displace the carrier and therein translate the
assembled planet gears and bearings to a position of lowest load
resulting in the carrier not rotating around a fixed centre but
orbiting. At low speeds this will not be an issue but at higher
speeds the high inertia of the carrier and planet gear assembly
will prevent the carrier responding to the manufacturing tolerances
resulting in high radial accelerations and vibrations. As the
planet carrier is linked to the fan shaft, the carrier radial
displacements will be reacted on the fan bearings and
structures.
If the input and output shafts and ring gear attachments are
directly connected to the to the respective components then
torsional twist can occur that will result in gear mesh
misalignment with uneven gear flank loading causing overloading
that can result in premature gear failures. Where such misalignment
occurs gear tooth profile modification needs to be applied to avoid
excessive load conditions.
It will be appreciated that the gearbox arrangement allows a
gearbox that is of reduced size and lighter than conventional
gearboxes as the flexibility helps to minimise loading variations
which would otherwise have to be compensated for by providing
increased component size. This has the additional effect of
efficient use of installation space and a reduced fuel burn due, in
part, to the lower weight. Lower weight also has a beneficial
impact the sizing of the engine mount structural parts.
Further benefits may be increased gearbox reliability as isolation
will limit the number of unknown and magnitude of load cases the
gearbox components will be exposed to, an opportunity for optimal
gas path definition, minimum tooth profile correction, reduced
engine vibration.
The planet carrier support roller bearings can direct gyroscopic
loads into the bearing structure and prevent additional gear mesh
and bearing loads. Reduced leakage from oil transfer coupling can
minimise oil supply to gearbox resulting in reduced heat to oil and
oil cooling capacity requirements.
* * * * *